Method and apparatus for converting germ

ABSTRACT

A method for converting germ (G) provides: 
         to subject germ (G) to a first hydrolysis ( 2 ) for converting starch associated to germ (G) in dextrins (D);    downstream the first hydrolysis ( 2 ), to subject germ (G) to a first separation ( 3 ), obtaining a fraction containing dextrin (D) and a first portion of oil (H) and proteins (L) associated to germ (G), separated from the latter purifying it;    to subject the purified germ (G) to grinding ( 4 );    to subject the ground germ (G) to a second hydrolysis ( 5 ) for hydrolyzing the proteins (L) of germ (G);    downstream the second hydrolysis ( 5 ), to subject germ (G) to a second separation ( 6 ) obtaining a fraction containing bran (C), peptides and not hydrolyzed proteins which are separated from the remaining part of germ (G) consisting of a mixture containing amino acids (A) and a second portion of oils (H);    to subject the mixture containing oils (H) and amino acids (A) to a third separation ( 7 ) getting a solution of amino acids (A) separated from the remaining part of germ (G) substantially consisting in the second portion of oils (H); to store said second portion of oils (H).

TECHNICAL FIELD

The present invention relates to vegetable product processing and itrefers to a method and an apparatus for converting germ extracted fromcorn grains or other similar agricultural products.

BACKGROUND ART

There are known methods and apparatuses or plants capable to extractoils and bran from germ through hot toasting and pressing of ground germin order to separate a part of the oils from bran. The large amount ofoil left in the bran is extracted through an organic solvent, mainlyhexane, and stored with the pressing oil.

The main drawback of said known methods and apparatuses consists in thatthe hexane is highly inflammable and toxic, obliging to build complexand expensive apparatuses with antiexplosive characteristics andprovided with special safety devices that however can not eliminate therisk of accidents or health damages for the apparatus staff and thecustomers.

Other drawback of known methods and apparatuses consists in that theycause the loss of a large amount of vitamins, pigments and activeprinciples of the oil. Further drawback of known methods and apparatusesconsists in that they provide bran enriched with not separable germproteins which is not optimal for animal feeding. In fact, since themonogastric animals use the proteins and only a small quantity of brancellulose, while the poligastric animals use the cellulose and theyassume only a small amount of proteins, the enriched bran obtained bythe known methods cause waste of foods and of animal chemical energy.

Other drawback consists in the protein denaturation and in the loss ofamino acids and of simple sugars and therefore in the reduction of thedigestibility of fodders obtained by the known methods and apparatuses.

Further drawback of known methods and apparatuses consists in that theyrequire a lot of water and energy and they produce polluting mud.

Documents U.S. Pat. No. 1,892,449 discloses the use of enzymes such asdiatase which hydrolyses starch and pepsin which hydrolyses protein toassist in liberating oils such as corn oil.

DISCLOSURE OF THE INVENTION

Object of the present invention is to propose a method and an apparatuscapable to provide oils without using organic solvents and thus safe forthe production workers and for the feeding.

Other object of the present invention is to propose a method and anapparatus fit to provide digestible oils and without remarkable lossesof vitamins, pigments and active principles.

Further object of the present invention is to propose a method and anapparatus capable to provide germ proteins, also separated and notdenatured and thus highly digestible and safe.

Other object of the present invention is to propose a method and anapparatus capable to provide amino acids, sugars, alcohol, enriched branand other products for human feeding and for fodders, without requiringto use organic solvents.

Other object of the present invention is to propose a method and anapparatus capable to reutilize the distillation water and its thermalenergy in order to reduce the energetic costs and the pollution.

BRIEF DESCRIPTION OF THE DRAWINGS

The characteristics of the present invention are underlined in thefollowing with particular reference to attached drawings, in which:

FIG. 1 shows a flowchart of the method object of the present inventionin which the phases are represented by rectangles and the initial,intermediate and final products are represented by circles;

FIG. 2 shows a schematic and partial view of the apparatus of thepresent invention.

BEST MODE OF CARRYING OUT THE INVENTION

With reference to FIG. 1, numeral 1 indicates the method for convertinggerm object of the present invention.

The germ G is obtained via mechanical separation from corn grains orkernel, carried out in a mill; the germ G can be also extracted fromsoy, wheat or other cereals.

The surface of said germ G is associated to residual products of theseed, from which the germ has been mechanically separated; the residualproducts include starch and other materials such as proteins and oils.The method 1 provides also the use of the germ without starch GG,derived by starch extraction processes carried out in production plantthereof.

The method for converting the germ G, in sequence provides:

-   -   to subject the germ G mixed with a liquid, such as water, to a        first hydrolysis 2 of amylolytic type executed at around 95° C.        through alpha-amylase enzyme and a respective additive for        converting starch associated to germ G in dextrins D;    -   downstream the first hydrolysis 2 to subject the germ G to a        first separation 3, by centrifugation, obtaining a fraction        containing dextrin D and a first portion of oils H and proteins        L associated to germ G separated from the latter, which is so        purified from starch and associated substances;    -   to subject germ without starch GG to mixing 8 with the purified        germ G and with liquid, such as water;    -   to subject the purified germ G, GG, to grinding 4 of humid and        fine type;    -   to subject the ground G, GG to a second hydrolysis 5, of        proteolytic type, operated at temperatures ranging from around        50° C. to around 70° C. through a respective enzyme and a        related additive, for hydrolyzing at least part of the remaining        proteins L of germ G, GG;    -   to subject the germ G, GG to a second separation 6, through        forced decantation, obtaining a fraction containing bran C,        peptides and proteins not hydrolyzed separated from the        remaining part of germ G, GG consisting a mixture containing        amino acids A and a second huge portion of oils H;    -   to subject the mixture containing oils H and amino acids A to a        third separation 7, through centrifugation, obtaining a solution        of amino acids A separated by the remaining part of germ G and        mainly consisting of second portion of oils H;    -   to store said second portion of oils H.

The fraction containing bran C, peptides and proteins not hydrolyzed issubjected to a first desiccation 10 to obtain dried bran C charged withpeptides and proteins.

The method 1 provides to subject the fraction containing dextrins D andthe first portion of oil H and proteins L of the germ G, separated fromthe latter by first separation 3, to a fourth separation 9, carried outby centrifugation, obtaining a solution including dextrins D andproteins L separated from the first oil portion H. This last portion isfit to be stored together with the second portion of oils H.

The solution including dextrins D and proteins L is subject, insequence, to acidification 12, obtained through organic or mineral acidsat a temperature ranging between 50° C. and 70° C., and to a fifthseparation 13, carried out by centrifugation, to obtain separatesolutions of dextrins D and of proteins L.

The method 1 provides to subject the solution of proteins L to thesecond hydrolysis 5 together with the ground germ G, GG or,alternatively, to a second desiccation 14 in order to obtain dryproteins L for storage.

The solution of dextrins D is subjected to a third hydrolysis 15,through respective enzyme and additive, to obtain from the dextrins Dsugars Z, mainly consisting of glucose.

Sugars Z are subjected to a second concentration 16 to obtainconcentrated sugars Z or, alternatively, they are subjected, insequence, to fermentation 17, through yeasts T, and to distillation 18obtaining, separate, a liquid Q and alcohols E; these last for storage.

The liquid Q is subjected to a sixth separation 19, by centrifugation,to separately obtain an aqueous liquid S, almost without solid residualproducts and in solution, and fermentation yeasts T for storage. Theaqueous liquid S is used for adding liquid to the germ G in the firsthydrolysis 2 and in the mixing 8 recycling water and the distillationthermal energy.

The method 1 also provides the use of aqueous liquid S for cooking corngrains to obtain a sanified food.

The amino acid solution A, obtained from the third separation 7, issubjected to a first concentration 11 obtaining concentrated amino acidsA for storage.

The method provides that the separations third 7, fourth 9, fifth 13 andsixth 19 are obtained through vertical type centrifugation.

The apparatus for converting germ G of the present invention includesfirst container and moving means 50 including a hopper and a conveyorfor filling a tank, provided with water delivering means 61, with germ Gcoming from a mill, or similar, and obtained from corn grains, soy, heator other cereals. The germ G is associated with fragments of grainendosperm, or seeds, containing starch, oils, proteins and dextrins inremarkable quantity and depending on the source material and on theprevious performed processes.

The first container and moving means 50 are in cascade connected to:

-   -   a station of first amylolytic hydrolyses 53;    -   germ separating means 65 having an exit for a fraction        containing at least oils, proteins and dextrins associated to        germ G and a separate exit for the germ G purified from the        associated substances;    -   fine grinding means 71 of the purified germ G, whose inlet is        connected to the respective outlet of the germ separating means        65;    -   a station of second proteolytic hydrolyses 54 for converting        proteins of germ G in amino acids;    -   protein fraction separating means 67 having an outlet for a        fraction including bran, peptides and not hydrolyzed proteins        and a separate outlet for oils and amino acids;    -   amino acids separating means 73 whose inlet is connected to the        outlet for oils and amino acids of protein fraction separating        means 67 and having an amino acids outlet connected to        concentration means 74 in order to provide concentrated amino        acids A and a separate outlet for a oily fraction H.

The germ separating means 65, for separating the protein fraction 67 andthe amino acids 73, consist of forced decanters, or horizontal orvertical centrifugal separators.

It is also provided that the protein fraction separating means 67 andthe amino acids separating means 73 can be integrated in a single deviceof tricanter type, having three separate outlets for the fractionincluding bran, peptides and not hydrolyzed proteins, for the aminoacids N and for the oily fraction H.

The apparatus includes mixing means 30 having an inlet and an outletinterconnected between the outlet for the purified germ G of the germseparating means 65 and the inlet of grinding means 71 and having afurther inlet connected to second container and moving means 31 of germG coming from starch separating apparatuses and thus almost withoutendospermatic material and consequently already purified from theproducts associated thereof.

The first hydrolyses station 53 includes heat exchanger means 64inserted in the inlet and outlet connections of at least one of thehydrolysis stations 53, 54 for heat regeneration.

The outlet for the fraction including bran, peptides and not hydrolyzedproteins of the protein fraction separating means 67 is connected todesiccation means 69 to provide bran, not hydrolyzed proteins and driedpeptides for animal use, for instance.

The outlet for the fraction containing oils, proteins and dextrins ofthe germ separating means 65 is connected to oil separating means 33provided with an outlet for a oily fraction H and an outlet for afraction containing proteins and dextrins.

This last outlet is connected in cascade to acidification means 79, forthe insolubilization and precipitation of proteins, to dextrinsseparating means 34 having an outlet for dextrins and an outlet forproteins in flow communication with the second hydrolyses station 54.

The outlet of oily fractions H of the amino acids separating means 73and oil separating means 33 flow into a oil tank, of known type and notshown.

The dextrins exit of the dextrins separating means 34 is connected incascade to a third hydrolyses station 35 for converting the dextrins insugars, to fermentation means 36 for converting sugars in alcohol, to adistillation station 57 provided with an outlet for an aqueous liquid Scontaining yeasts and with an outlet for alcohol E.

The fermentation means 36 are provided with fermentation yeast feedingmeans and they are connected to water delivering means 61.

The outlet of the aqueous liquid S of the distillation station 57 isconnected to yeast separating means 75, of centrifugal type, an outletof which provides yeast T and the remaining outlet provides aqueousliquid S depurated from yeasts and connected to the water deliveringmeans 61 for feeding or helping to feed with water these last.

Each hydrolysis station first 53, second 54 and third 35 includes athermoregulated enzymatic room 59 into which respective enzymedelivering means 58 and additive delivering means 60 flow for insertingin the rooms 59 respective enzymes and additive.

Each hydrolysis station 53, 54, 35 includes storage means 62, 63positioned upstream and downstream the related enzymatic room 59,consisting of tanks fit for the continuity of the production flow.

The enzymatic room 59 of the first hydrolysis station 53 is in flowcommunication with water delivering means 61 for charging germ withwater.

The apparatus also includes a plurality of pipes, valves, heaters,sensors, pump means and intermediate tanks, known and not shown, fit forthe circulation and the adjustment of production.

The main advantage of the present invention is to provide a method andan apparatus capable to provide oils without using organic solvents andthus safe for the production workers and for the feeding.

Other advantage of the present invention is to provide a method and anapparatus for obtaining amino acids, sugars, alcohol, oils, bran andproteins also separated and other products not denatured and thus highlydigestible and safe for human feeding and for fodders.

Other advantage is to provide a method and an apparatus capable toreutilize the aqueous liquid and its thermal energy in order to reducethe water and energy consumption.

Other advantage is to provide an apparatus fit for carrying out acontinuous production with continuous feeding.

1) Method for converting germ (G) characterized in that provides: tosubject germ (G) to a first hydrolysis (2) for converting starchassociated to germ (G) in dextrins (D); downstream the first hydrolysis(2), to subject germ (G) to a first separation (3), obtaining a fractioncontaining dextrin (D) and a first portion of oil (H) and proteins (L)associated to germ (G), separated from the latter purifying it; tosubject the purified germ (G) to grinding (4); to subject the groundgerm (G) to a second hydrolysis (5) for hydrolyzing the proteins (L) ofgerm (G); downstream the second hydrolysis (5), to subject germ (G) to asecond separation (6) obtaining a fraction containing bran (C), peptidesand not hydrolyzed proteins which are separated from the remaining partof germ (G) consisting of a mixture containing amino acids (A) and asecond portion of oils (H); to subject the mixture containing oils (H)and amino acids (A) to a third separation (7) obtaining a solution ofamino acids (A) separated from the remaining part of germ (G)substantially consisting in the second portion of oils (H); to storesaid second portion of oils (H). 2) Method according to claim 1characterized in that provides to subject starchless germ (GG) with germ(G) purified from starch to mixing (8), downstream the first separation(3) and upstream the second hydrolysis (5). 3) Method according to claim1 characterized in that provides: to subject the fraction containingdextrins (D) and the first portion of oil (H) and of proteins (L),associated to the germ (G) and separated from the latter through thefirst separation (3), to a fourth separation (9) obtaining a solutionincluding dextrins (D) and proteins (L) separated from the first portionof oil (H); to collect the first portion of oils (H) together with thesecond portion of oils (H). 4) Method according to claim 3 characterizedin that provides to subject the solution including dextrins (D) andproteins (L), in sequence, to acidification (12) and to a fifthseparation (13) for obtaining separated solutions of dextrins (D) andproteins (L). 5) Method according to claim 4 characterized in thatprovides to subject the solution of proteins (L) to second hydrolysis(5). 6) Method according to claim 4 characterized in that provides tosubject the solution of proteins (L) to a second desiccation (14) toobtaining dried proteins (L). 7) Method according to claim 4characterized in that provides to subject the solution of dextrins (D)to a third hydrolysis (15) to obtain sugars (Z) from the dextrins (D).8) Method according to claim 7 characterized in that provides to subjectsugars (Z) to a second concentration (16) to obtain concentrated sugars(Z). 9) Method according to claim 7 characterized in that to subjectsugars (Z), in sequence, to fermentation (17) and to distillation (18)obtaining, separated, a liquid (Q) and alcohols (E) and to store theselast ones. 10) Method according to claim 9 characterized in thatprovides to realize the fermentation (17) through yeasts (T). 11) Methodaccording to claim 9 characterized in that to subject the liquid (Q) toa sixth separation (19) to obtain, separated, an aqueous liquid (S),almost without solid residues and in solution, and the fermentationyeasts (T) for storage. 12) Method according to claims 2 and 11characterized in that provides to use, at least partially, the aqueousliquid (S) to add liquid to the germ (G) during at least one between thefirst hydrolysis (2) and the mixing (8). 13) Method according to claim11 characterized in that provides to use, at least partially, theaqueous liquid (S) for cooking corn grains to obtain a sanified food.14) Method according to claim 1 characterized in that provides tosubject the fraction containing bran (C), peptides and not hydrolyzedproteins to a first desiccation (10) to obtain dried bran (C) chargedwith peptides and proteins. 15) Method according to claim 1characterized in that provides to subject the solution of amino acids(A), obtained by third separation (7), to a first concentration (11),obtaining concentrated amino acids (A) and to store these last. 16)Method according to claim 1 characterized in that provides to carry outthe first hydrolysis (2) of amylolytic type through alpha-amylase typeenzyme and a respective additive. 17) Method according to claim 1characterized in that provides to realize the second hydrolyses (5) oftype proteolytic through a respective enzyme and a related additive. 18)Method according to claim 7 characterized in that provides to effect thethird hydrolysis (15) through at least a respective enzyme and arespective additive. 19) Method according to claim 4 characterized inthat provides to obtain the acidification (12) at least through organicor mineral acids at a temperature ranging between 50° C. and 70° C. 20)Method according to claim 1 characterized in that provide to obtain atleast one of the separations first (3), second (6), third (7), fourth(9), fifth (13) and sixth (19) through forced decantation, vertical orhorizontal centrifugation. 21) Apparatus for converting germcharacterized in that includes, in cascade connection, at least: firstcontainer and moving means (50) of the germ (G); a station of firstamylolytic hydrolyses (53); germ separating means (65) having an exitfor a fraction containing at least oils, proteins and dextrinsassociated to germ (G) and a separate exit for the germ (G) purifiedfrom the associated substances; fine grinding means (71) of the purifiedgerm (G), whose inlet is connected to the respective outlet of the germseparating means (65); a station of second proteolytic hydrolyses (54)for converting proteins of germ (G) in amino acids; protein fractionseparating means (67) having an outlet for a fraction including bran,peptides and not hydrolyzed proteins and a separate outlet for oils andamino acids; amino acids separating means (73) whose inlet is connectedto the outlet for oils and amino acids of protein fraction separatingmeans (67) and having an amino acids outlet connected to concentrationmeans (74) in order to provide concentrated amino acids (A) and aseparate outlet for a oily fraction (H). 22) Apparatus according toclaim 21 characterized in that includes mixing means (30) having aninlet and an outlet interconnected between the outlet for the purifiedgerm (G) of the germ separating means (65) and the inlet of grindingmeans (71) and having a further inlet connected to second container andmoving means (31) of purified germ (G). 23) Apparatus according to claim21 characterized in that each hydrolysis station first (53) and second(54) includes a thermoregulated enzymatic room (59) into whichrespective enzyme delivering means (58) flow. 24) Apparatus according toclaim 23 characterized in that each enzymatic room (59) of thehydrolysis stations, first (53) and second (54), has additive deliveringmeans (60). 25) Apparatus according to claim 23 characterized in that atleast one of the hydrolysis stations first (53) and second (54) includeswater delivering means (61) in flow communication with the respectiveenzymatic room (59). 26) Apparatus according to claim 21 characterizedin that each hydrolysis station, first (53) and second (54), includesstorage means (62), positioned upstream and downstream the relatedenzymatic room (59). 27) Apparatus according to claim 21 characterizedin that at least one of the hydrolysis stations (53, 54) includes heatexchanger means (64) inserted in the inlet and outlet connections of atleast one of the hydrolysis stations (53, 54). 28) Apparatus accordingto claim 21 characterized in that the protein fraction separating means(67) and the amino acids separating means (73) are integrated in atricanter device. 29) Apparatus according to claim 21 characterized inthat that the outlet for the fraction including bran, peptides and nothydrolyzed proteins of the protein fraction separating means (67) isconnected to desiccation means (69) to provide bran, not hydrolyzedproteins and dried peptides (C). 30) Apparatus according to claim 21characterized in that the outlet for the fraction containing oils,proteins and dextrins of the germ separating means (65) is connected tooil separating means (33) provided with an outlet for an oily fraction(H) and an outlet for a fraction containing proteins and dextrins incascade connection to acidification means (79) for the insolubilizationof proteins and dextrins, to dextrins separating means (34) having anoutlet for the dextrins and an outlet for the proteins, in flowcommunication with the second hydrolyses station (54). 31) Apparatusaccording to claim 30 characterized in that the dextrins outlet of thedextrins separating means (34) is connected in cascade to a thirdhydrolyses station (35) for converting dextrins in sugars, tofermentation means (36) for converting sugars in alcohol, to adistillation station (57) provided with an outlet for an aqueous liquid(S), containing yeasts and an outlet for alcohol (E). 32) Apparatusaccording to claim 31 characterized in that the outlet of the aqueousliquid (S) of the distillation station (57) is connected to yeastseparating means (75) an outlet of which provides yeasts (T) and theremaining one provides the aqueous liquid (S) purified from the yeasts,and is connected to the water delivering means (61) to feed these lastones. 33) Apparatus according to claims 25 and 32 characterized in thatthe outlet of the aqueous liquid (S) purified from the yeasts of theyeast separating means (75) feeds at least the water delivering means(61). 34) Apparatus according to claim 31 characterized in that thethird hydrolyses station (35) includes a respective thermoregulatedenzymatic room (59), into which respective delivering means of enzyme(58) and additive (60) flow, and it includes respective storage means(62) positioned upstream and downstream said enzymatic room (59).